f 190 - fascan international · c i introduction f 190.24 2 fassi crane f 190.24 use and...

c I

1

FASSI CRANE

F 190.24use and maintenanceEXTRA CE version 97.01.23 Valid from serial number *0914*

INDEX

Chapter I INTRODUCTION page 2

II SAFETY NORMS page 3

III INSTRUCTIONS FOR CRANE USE page 6

IV IDENTIFICATION OF THE CRANE MODEL page 7

V TECHNICAL DATA page 8

VI CRANE NOMENCLATURE page 10

VII SAFETY AND PROTECTION DEVICES page 12

VIII LOAD LIMITING DEVICE - LIFTING MOMENT

LIMITING DEVICE (A RICHIESTA) page 14

IX CONTROLS TO STABILIZE THE VEHICLE page 16

X CONTROLS TO OPERATE THE CRANE page 25

XI USE OF IMPLEMENTS page 29

XII MAINTENANCE INSTRUCTIONS page 34

XIII POSSIBLE FAULTS page 38

XIV HYDRAULIC SCHEMATICS page 39

XV OIL AND LUBRICANT CHARACTERISTICS page 44

A INSTRUCTION AND WARNING PLATES page 45

B CAPACITY PLATES page 48

c IINTRODUCTIONF 190.24

2

FASSI CRANE

F 190.24use and maintenance

This instruction manual describes the FASSI CRANE F190.24.

The fitment must be carried out in accordance with the instructions givenby the Manufacturer in the manual for hydraulic crane fitting.

The Manufacturer declines all responsibility and guarantee if the fitting isentrusted to workshops without sufficient technical capability to carry outthe work in conformity.

As well as the principal safety norms, this manual contains a descriptionof the crane and the instructions for use and maintenance.

The crane must only be operated by responsible persons, previouslyinstructed and authorized.

THANK YOU FOR SELECTING ONE OF OUR CRANES.

SAFETY NORMS

( ! ) This symbol draws your attention on the points concerning safety.It means: WARNING! BE CAREFUL!

IT CONCERNS YOUR SAFETY!

!ATTENTION!

READ THIS MANUAL CAREFULLY prior to use of the crane or any maintenance.A few minutes spent now could save time and labour later.Be sure that the unit has been installed, inspected and tested in accordance with thelocal legal requirements.

To operate the crane it is necessary to fully understand its working, safety and war-ranty norms.

Check that protections are in their place and that all safety devices are fitted and active.

Warning plates, as well as instruction and operation plates must be replaced when nolonger readable or missing. (See chapters A - B)

Do not run the engine in a indoor area without first making sure there is adequate ven-tilation. Fit a suitable extension tube to the vehicle exhaust pipe to take the fumesaway from the working area.

Stabilize the vehicle by means of the outrigger rams, checking that they rest on a solidbase; if in doubt use special larger outrigger base plates (available on request). (Seechapter IX)

Stabilize the vehicle on a horizontal plane with a maximum tolerance of 1,5 degrees.

Check that the taps of the outrigger rams safety check valves are closed. Never opera-te the outriggers when the crane is loaded.

Remember thatthe stabil i ty ofthe unit (crane-vehicle) is onlyguaranteed bythe maximumlateral extensionof the outriggers.

Should visibility be insufficient, make sure that control stations are properly lighted soas to ensure safety while operating control functions and allow reading of the plates.

Before manoeuvering a load check that the working area is adequate and properlylighted for your crane.

Make sure that the hook is always free to rotate on its pin and that nothing obstructsits vertical positioning.

Check the efficiency of the hook safety catch.

Carefully inspect the load rigging and the condition ofropes or chains.Make sure that the lifted load is balanced.

The pallet fork must be connected to the crane hook bymeans of a chain having at least 3 rings.

Hook up the load, checking that it does not exceed the capacity indicated on the liftingdiagram specific to each load configuration.

It is absolutely prohibited to walk or stopunder a suspended load and for unauthori-zed persons to be within the working area.

Avoid swinging the load above the controlstation; in cases where the load is tooclose, the crane must be operated fromthe opposite side.

c IISAFETY NORMS

V_GRU_FASSI

3

}3

It is absolutely prohibited to load or unload underor in proximity of electric lines.

(!) The minimum distance from electric lines is, according to CEN norms, 5 meters, except for otherwise prescribed by national norms.

For cranes with top seat controls, it is necessaryto use a ladder to reach the control station.

When operating from the top seat, stay within itsside safety guards.

Do not rotate the crane before the load islifted, do not operate with sudden move-ments, activate the controls with slowand progressive movements.Rotate slowly and with care paying atten-tion to the stability of the vehicle.

With vertical lift, on hydraulic and mecha-nical extension, rotate slowly in order toavoid side-skidding.

Do not move the vehicle if a load issuspended on the crane.

Do not utilize the crane for pushpull (F),lateral (F) or sideways (F) operations.

Under no circumstances interfere with the safety and protection devices.

The vehicle/crane are not left unless the power take off is disengaged and the load ison the ground.

At the end of the job and prior to drivingthe vehicle the crane must be folded. If the booms are to be laid on the bodyor on the load, they must be blocked toprevent possible sideways movements.Outrigger rams must be lifted and re-entered within the overall width of thetruck and safety devices locked.

Check that the taps of the outriggerrams safety check valves are closed.

Disengage the power take off.

To avoid hitting bridges or tunnels checkand record the overall height of your cranein the folded position or in laid position inthe body or on the load. Always respect andpay proper attention to road signs placed inproximity of such obstacles.

SAFETY NORMSV_GRU_FASSI

4

c II

INSTRUCTIONS FOR CRANE USE

The use of the crane is reserved to authorized personnel, instructed inadvance, who has to strictly conform to the safety norms and instructionscontained in the instruction manual supplied with the crane.

1 — Only authorized persons are allowed to operate the crane.

2 — The crane must be used on firm, level ground.

3 — Check that the vehicle hand brake is on and that the wheels are chocked.

4 — Before every operation make sure that:— no-one is within the working area of the crane— the safety devices are in place and operative — the minimum safe working distances from power

lines are observed.

5 — Stabilize the vehicle by the outrigger rams, making sure that:— the lateral supports are fully extended— the wheels are in contact with the ground and the

suspension is not completely unloaded— the outriggers safety taps are closed.

6 — Use the crane in accordance with the use and mainte-nance manual, making sure that: — the load and radii are within the maximum limits

shown on the crane capacity plate— the crane is used progressively avoiding sudden

load movements— swinging or dragging of the load is avoided— the load is lifted before rotating.

7 — When using implements protect the crane workingarea with a barrier.

8 — The vehicle/crane are not left unless the power takeoff is disengaged and the load is on the ground.

9 — Before driving the vehicle make sure that the outriggers are fully retracted and re-entered, the safety taps closed and the crane is in folded position.

INSTRUCTIONS FOR CRANE USE

V_GRU_FASSI

5

c III

THESE INSTRUCTIONS FOR THE USE OF THE CRANE COINCIDE WITH THOSE OF THEPLATE DE1771 (fig. 1a) OR DE2499 (fig. 1) PLACED NEXT TO THE CRANE CONTROLS.

fig. 1VERTICAL VERSION

fig. 1aHORIZONTAL VERSION

IDENTIFICATION OF THE CRANE MODELV_GRU_FASSI

6

c IV IDENTIFICATION OF THE CRANE MODEL

Essential data for the identification of the crane are given on the plate DE1661used for the CE mark and fixed to the base. (Fig. 2)

1 — Crane model2 — Serial Number3 — Year of manufacturing

The model, the version of the crane, the year of manufacturing and the serialnumber are stamped on the base in the following sequence:

*Fxxx.yy*2*0002*

( !) UNDER NO CIRCUMSTANCES SHOULD THE DATA MARKED ON THE PLATE AND PUNCHED ON THE BASE BE ALTERED.

It is essential to give the correct crane model and serial number, when youcontact the Service and Parts Department.

The exact crane model, serial number and description of implements willenable FASSI Service Department to give a rapid and efficient response.

A further metallic plate (fig.4) fixed to the crane bythe installer, quotes the identifying data of theequipment and the final CE mark.

1 Name of the installer who applied the finalCE mark

2 Crane mark, model and serial number3 Vehicle mark, model and chassis number4 Year of mounting

fig. 2

GRU MODELLOCRANE MODEL

N° DI SERIESERIAL NUMBER

ANNO DI COSTRUZIONEMANUF. YEAR

24021 ALBINO (BG) ITALYFAX 39 35 755020

1

2

3

serial no.

year of manufacturing

version /.22 /.23 /.24

model

CRANE-MARK AND MODELSERIAL NUMBER

TRUCK-MARK AND MODELTRUCKFRAME SERIAL NUMBER

YEAR OF MOUNTING

2

3

1

4

fig. 4

IdentificationplatePunching

fig. 3

TECHNICAL DATAF 190.24

7

c VTECHNICAL DATA

The design of this crane has been carried out in respect of DIN 15018 norms,fatigue test classification H1B3 .

The crane can operate, intermittently, with lifting devices other than the hook.The dimensions and the capacity of the implements must be proportionedwith crane performances.

Lifting capacity

tm 16,20

F 190.24

Standardreach

m 12,60

Hydraulicextension

m 7,90

Rotation arc

400°

Rotation torque

kNm 32,5

Workingpressure

MPa 28,5

Pump capacity

l/min 45

Oil tank capacity

l 120

Crane weight

kg 2583

F190.24

ST190

TECHNICAL DATAF 190.24

8

c V F190.24

F190.24

MASSIMA ALTEZZA SOTTOGANCIO.

HAUTEUR MAXIMUM SOUS CROCHET.

MAXIMUM HOOKING POSITION.

MAXIMALHOEHE BIS KRANHAKEN.

CO 1053

— MEZZERIA TIRANTI

— FIXING ROD CENTER DISTANCE

— LIGNE MEDIANE TIRANTS

— ABMESSUNG DER BEFESTIGUNGSBRIDEN

M30 x 2

PESO GRU CON SERBATOIO NON RIFORNITO, STABILIZZATORI STANDARD

WEIGHT OF THE CRANE WITH EMPTY TANK, STANDARD SATBILIZATION

POIDS DE LA GRUE AVEC RESERVOIR VIDE, STABILISATION STANDARD

KRANGEWICHT MIT LEEREM TANK UND STANDARBSTUTZUNG

kg 2.583

lbs 5.694

1.704 5’ 7”1.704 5’ 7”2.254 7’ 5”5.662 18’ 7”

ABCD

EXTRA

✱ CON TUBAZIONI SUPPLEMENTARI

✱ WITH SUPPLEMENTARY HOSES

✱ AVEC TUYAUTERIE

SUPPLEMENTAIRE

✱ MIT ZUSAETZLICHEN SCHLAEUCHEN

PESI, DIMENSIONI E POSIZIONE

BARICENTRO.

POIDS, DIMENSIONS ET POSITION

DU BARYCENTRE.

WEIGHT, DIMENSIONS AND

BARYCENTRE POSITION

GEWICHTE, ABMESSUNG UND POSITION

DES KRANSCHWERPUNKTE.

CO 1026

CRANE NOMENCLATURE

V2_GR4_160»190c VI

9

CRANE NOMENCLATURE

— Version with ground controls for crane and outriggers— Version with top seat controls (fig. 5a) for crane by hand cables

(optional) (fig. 5)

Pos. Description

1 — Outrigger rams2 — Outrigger supports 3 — Base4 — Rotation cylinders5 — Deviator crane - outriggers6 — Outrigger multifunction deviator7 — Outrigger multifunction transmission8 — Distributor bank9 — Double control

10 — Column11 — Inner ram12 — Inner boom13 — Outer ram 14 — Outer boom15 — Booms extension rams16 — Extension boom sections17 — Lifting hook18 — Oil tank19 — Manual extensions (optional)20 — Seat (optional)21 — Hand-cables for crane (optional)

— Version with ground controls for outriggers and top seat controls for crane (fig. 6)

Pos. Description

1 — Outrigger rams2 — Outrigger supports 3 — Base4 — Rotation cylinders5 — Deviator crane - outriggers6 — Outrigger multifunction deviator 7 — Outrigger multifunction transmission8 — Column9 — Seat

10 — Distributor bank11 — Inner ram12 — Inner boom13 — Outer ram14 — Outer boom15 — Booms extension rams16 — Extension boom sections17 — Lifting hook18 — Oil tank 19 — Manual extensions (optional)

fig. 5

fig. 6

12

21

20

107

42

9

1

1

3

82

4

5

6

18

11

1314

16

19

17

15

fig.5a

12

10

7

4

1

2 3

8

4

5

6

1811

1314

16

19

17

15

1

2

9

SAFETY AND PROTECTION DEVICES

— Version with ground controls for crane and outriggers— Top seat controls (fig. 7a) for crane by hand-cables (optional) (fig. 7)

Pos. Description

1 — Tap and check valve for outrigger rams2 — Check valves for rotation control (flow regulators) 3 — Check valve for inner ram4 — Check valve for outer ram5 — Check valve for booms extension rams6 — Lifting moment limiting device assembly 7 — Control panels 8 — Parachute valves 9 — Rotation limiting device 10 — Main pressure valve (crane - outriggers)11 — Main pressure valve (crane)12 — Auxiliary valves (crane)13 — Levers guard14 — Hook safety device15 — Safety device for outriggers supports16 — Outer boom sliding sections locking device

(only for the crane version “C”)

— Version with ground controls for outriggers and top seat controls for crane (fig. 8)

Pos. Description

1 — Tap and check valve for outrigger rams2 — Check valve for rotation control3 — Check valve for inner ram4 — Check valve for outer ram 5 — Check valve for booms extension rams6 — Lifting moment limiting device assembly7 — Control panel8 — Parachute valves 9 — Rotation limiting device10 — Main pressure valve (crane - outriggers)11 — Main pressure valve (crane)12 — Auxiliary valves (crane)13 — Levers guard14 — Safety device for outriggers supports15 — Hook safety device16 — Outer boom sliding sections locking device

(only for the crane version “C”)

(!) Before crane use check that safety and protectiondevices are fitted and active.

(!) Under no circumstances interfere with the safety and protection devices.

(!) Interference with the check valves and removal of the lead seals remove the Manufacturer and invalidate the warranty.

(!) Use the ladder for the access to the top seat.

c VII

10

SAFETY AND PROTECTIONDEVICESV2_GR4_160»190

fig. 7

fig. 8

fig.7a

LIFTING MOMENT LIMITING DEVICE AND CONTROL PANELS

A characteristic which permits the classification of cranes is their lifting capa-city or maximum lifting moment. The moment is defined by the value obtainedfrom the product of the load to be lifted (in kg) by its distance (in meters) fromthe centerline of the crane rotation.The device called “lifting moment limiting device” preserves the crane structu-re from overloads, as it prevents any movement whichincreases the value of the moment up to the maximum esta-blished value.

Lifting moment limiting device “INTELLIGENT TYPE”

This device is fitted close to the distributor, whose specificfunctions it uses. It utilises an electrohydraulic technology,preventing any movement which causes an increase in thepressure induced by the load in the inner and outer rams ofthe crane (and in the outer ram for the hydraulic extension iffitted), up to the “critical values” which have been established in thestructural test. These values, which are non-exceedable, determinethe intervention levels and provide the data for setting the device.

The lifting moment limiting device concernes the following manoeu-vres:— Inner boom descent; the inner boom lift is controlled by the general

main pressure valve of the distributor. — Outer boom lift.— Outer boom descent.— Extension of extension boom sections.— Winch rope lift (if fitted).— If hydraulic extension is fitted: extension outer boom lift.— Extension outer boom descent. — Extension of the jib extension booms section.

The device is based on hydraulic controls which are activatedwhen the intervention value is reached and block the move-ments of the relevant distributor levers in one or both direc-tions. Please remember that the device will return the lever of the elementbeing used to neutral position.The condition of intervention is operated by theposition of the outer boom (or, if hydraulic extension is fitted, the position ofthe extension outer boom), on which the electronic signal position (mercurylevel switch) is read by a special electrovalve. This determines the controls ofthe locking or unlocking (resetting) of the controls concerned.

The crane configurations (fig. 9a-b-c) (and the eventual hydraulic extension) indi-cate the manoeuvres which are allowed and not allowed by the device, in con-nection with the horizontal position of the crane and extension outer booms.

Lifting moment limiting device for two working areasIn case of one sector of the working area with no sufficient stability of the vehi-cle (e.g. sector in front of vehicle cab) the limiting device, by means of a spe-cial function, allows, using the rotation arc limiter as well as an adjustableelectro-hydraulic device, to operate with a reduction of the intervention level.

The reduction of the intervention level reduces the crane capacity values andthis reduction value is defined in the vehicle stability calculation.

Consequently the working area is divided in one sector (e.g. body side) wherethe crane works according to the capacity plate values and another sector(e.g. cab side) where it works with reduced capacity values.

The device has consequently two intervention levels which are activated in rela-tion to the sector of the crane working area always securing the vehicle stability.

LIFTING MOMENT LIMITING DEVICE AND

CONTROL PANELSV2_GR3_105»140_4

11

c VIII

fig. 9a

fig. 9b

fig. 9c

c VIIILIFTING MOMENT LIMITING DEVICE AND CONTROL PANELSV2_GR3_105»140_4

12

(!) ATTENTION (!)If the rotation stops by going through the working zone where the crane can ope-rate according to the capacity plate values to the one where it can operate accor-ding to the reduced values, it means that one of the following conditions is rea-ched:

- manoeuvre of a load bigger than the one admitted in the reducedsector defined in the vehicle stability calculation

- manoeuvre without load with (at least) one of the inner, outer rams of the crane or the jib (if fitted) extended till the stroke end.

The only one allowed manoeuvre is the crane rotation in the reversedsense, and consequently, an action which respectively allows to reducethe moment or to re-enter the inner ram(s), the crane outer ram, the jibouter ram.

Control panels

The electric control panels are placed next to each control station.

Layout of the control panel (fig. 10-12), positioned next to thedistributorpos. 1 — Stop button (STOP)

2 — Audible alarm push button (danger)3 — Orange warning light (90% of the capacity has been

reached)4 — Red warning light (activation of the limiting device)5 — White warning light (power on)7 — Fuse

Layout of the control panel (fig. 11) positioned on the doublecontrol side in the version with ground controls and on top seatin case of hand-cable controls pos. 1 — Stop button (STOP)

2 — Audible alarm push button (danger)3 — Orange warning light (90% of the capacity has been

reached)4 — Red warning light (activation of the limiting device)

If the white warning light 5 comes on, it confirms that the electric cir-cuit is active.

!NOTE! In the absence of electric power all crane functions willbe desactivated.

If the orange warning light 3 comes on during load handling, 90% ofthe capacity (lifting moment) has been reached.

If during operation the red warning light 4 comes on, the activationvalue of the lifting moment limiting device has been reached.

Any hidden danger situation for persons must be audibly alarmed bypressing the push button 2.

When there are serious, imminent and dangerous conditions for per-sons and things during load handling, operate on the stop button 1,which isolates all crane functions.

(!) ATTENTION (!)Do not walk on the lever guards of the liftingmoment limiting device positioned on the distribu-tors or electric control panels.

Do not use water to estinguish fire!

GROUND CONTROLS fig. 10

DOUBLE CONTROL SIDE fig. 11

TOP SEAT CONTROLS fig. 12

3 4

2

1

6

5

3 4

2

1

6

5

3 4 21

DE 1679 DE 1680

REACTIVATION button of crane functions and EMERGENCY exclusiontap of the lifting moment limiting device.

Firstly remove the protection guard. Then unscrew the three base fixingscrews and the four seat fixing screws (13 mm hexagonal spanner).

REACTIVATION button of crane functions in the absence of the electricpower.

(!) On the distributor it has been installed an electro-valve with a manuallocking function (fig. 13-13a) which allows to reactivate all the cranefunctions in case of absence of the electric power. Only in these conditions it is permitted to remove the lead seals whichprotects the device. Push the button and turn it into the clockwise sense; the button stays in stable and closed position.

(!) When the electric power is restablished, remember to put the button inits original position, turning it into the anti-clockwise sense.

EMERGENCY exclusion tap of the lifting moment limiting device

Every electrovalve is installed with a screwed tap (emergency exclusion tap),which must only be used in case of emergency, testing or other abnormalsituations when it is not possible to carry out any of the movements allowed bythe device. Only In these situations it is permitted to remove the lead sealswhich protect the device. Slacken the lock nut of the screwed tap fig. 14-15(14 mm hexagonal spanner), completely screw in the tap (5 mm allen key)and re-tighten the lock nut.

(!) ATTENTION (!)

When the operator uses this device, it means that he wishes to overridethe lifting moment limiting device in order to make some manoeuvres(which would be impossible with the device active) that bring themoment to within the level, but involve an overload condition. In such anemergency condition (where the lifting moment limiting devicehas beendisabled), the operator must be:- carefully consider the manoeuvres required to return to normal

working condtions;- calmly and carefully assess the type and scale of the hazards

arising from these manoeuvres and the possible reaction of thecrane (tipping over, frame overload, uncontrolled fall of the load due to a hydraulic system overload etc...);

- make all movements as slowly as possible to reduce the dynamicoverload to the minimum.

c VIIILIFTING MOMENT

LIMITING DEVICE AND CONTROL PANELS

V2_GR3_105»140_4

13

fig. 13 fig. 13a

After such emergency operations and prior to re-use of the crane, you mustimmediately go to FASSI authorised Center for testing the structureand re-sealing of the device.

(!) Interferences with the valves or removal of the lead seals release the Manufacturer from any responsibility and invalidate the warranty.

(!) ATTENTION (!)The presence of the lifting moment limiting device does not release theuser from the obligation to respect what is indicated on capacity platesand lifting curves.

ROTATION LIMITING DEVICE

When a sector of the working area exists in which the stability is insufficient(for example in the area in front of the cab) the permitted arc of rotation is limi-ted by means of an adjustable electro-hydraulic device which only allows ope-ration within the safe area. (fig. 16)When exceeding the “safe area” the rotation limiting device only allowsmanoeuvres which reverse the direction of rotation.If a reduction of capacity is necessary because of insufficient stability of thecomplete unit, new capacity plates must be fixed giving the derated capacityin accordance with the final stability test.

c VIIILIFTING MOMENT LIMITING DEVICE AND CONTROL PANELSV2_GR3_105»140_4

14 fig. 16

Crane with top seat controlCrane with ground controls fig. 14 fig. 15

c IXCONTROLS

TO STABILIZE THE VEHICLE

V2_GR4_160»190

15

CONTROLS TO STABILIZE THE VEHICLE

The outriggers rams prevent hurmful stresses both to the frame and to thevehicle suspensions on which the crane is mounted and assure the stability ofthe unit during load handling.

Supplementary beamsSupplementary beams (supplementary outriggers) are used in conjunctionwith the crane outriggers to ensure the vehicle stability during load handling.They are hydraulically extendable.

Supplementary outrigger ram extension max.beam code stroke interaxis

52185 550 mm 2132 mm Fixed56681 550 mm 3558 mm manual extension115B073 450 mm 3098 mm manual extension145B068 650 mm 4142 mm hydraulic extension145B070 340 mm 4142 mm hydraulic extension

Identification data of the supplementary beam are punched on the beam(fig.17) in the following sequence:

Example *145B070*0001*

serial no.

identification code

! ATTENTION !

(!) The crane stability is only guaranteed by the maximum lateralextension of the outrigger supports of the crane and supplementary outriggers (if fitted).

Be very careful during vehicle stabilization operation; make sure that no one isor transits in close proximity of the working area of the outriggers.

Check that they are applied on a solid base; the plate pressure of therams is:

19,4 daN/cm2 on a plate which diameter is 230 mm40,0 daN/cm2 on a plate which diameter is 160 mm

If needed use the special base plates (on request).

When stabilization is complete the wheels of the vehicle must still be incontact with the ground and the suspensions must not be fullyunloaded.Level the crane so as to operate on a horizontal plane.

The crane is supplied with outrigger supports having hydraulic sideextension. (On request hydraulic extra extendable supports).

The controls to stabilize the vehicle are activated only on ground level and onboth sides of the crane base.

fig. 17

Punching

(!) The controls to stabilize the vehicle are in conformity with the safety directives and enable the operator to activate the lateral extension of theoutriggers (outrigger supports and rams) only from the side where he canvisually check the operation.

The special construction concept of the outrigger control group whichcombines the functions of an 8 positions deviator with those of a distri-butor segment, allows to use the control lever for selecting and opera-ting the supports and the outrigger rams.

- The selection (support or ram) is effected, like on a deviator,by positioning the lever on the corresponding positionindicated by the function schematic (plates DE2298 andDE2297) placed on the controls.

- The control is effected by operating the lever like on adistributor; the stability of the selected position is guaranteedby an internal device.

The extension and re-enter ing of the suppor t and outr igger ramsindicated on the fig. 18-19 coincide with what indicated on the plates DE2298and DE2297 placed in dual side position on the base.

The symbols reported at side of each lever indicate the operating levers inrelation to their movement.

Lever function D - C

- Lever D Deviator crane - outriggers ( - E/S). Fig. 20a- Lever C Multifunction deviator for selecting and operating the supports and

the outrigger rams of the crane as well as the supplementaryoutriggers. Fig. 20-21

Control for outrigger support extension for the craneand the supplementary outriggers.

- Position lever D of oil diverter crane-outriggers ( - E/S) on E/S. Fig. 20b

- Open all the taps of the valves placed on the outriggerrams fig. 22.

- Disengage the locking devices of the outrigger supports by putting the levers A from the position of the fig. 23 tothe one of the fig. 23a.

Crane distributor side DE2298 fig. 18-20.

- Select the outrigger support E2 positioning the lever Cof the multifunction deviator on E2.

- Operate the lever to extend the support E2.- Select the outrigger ram S2 positioning the lever C

on S2.- Operate the lever to control the ram descent S2.- Select the support E3 positioning the lever C on E3. - Operate the lever to extend the support E3.- Select the ram S3 positioning the lever C on S3.- Operate the lever to control the ram descent S3.

c IXCONTROLS TO STABILIZE THE VEHICLEV2_GR4_160»190

16

C

fig. 21

Distributor side

fig. 18

Double control side

fig. 19

C

fig. 20

fig. 20a

D

c IXCONTROLS

TO STABILIZE THE VEHICLE

V2_GR4_160»190

17

N.B. The lever, if in other positions, does not allow any operations as asecurity device keeps it in free position.

Crane double control side DE2297 fig.19-21

- Select the support E1 positioning the lever C on E1.- Operate the lever to extend the support E1.- Select the ram S1 positioning the lever C on S1.- Operate the lever to control the ram descent S1.- Select the support E4 positioning the lever C on E4.- Operate the lever to extend the support E4.- Select the ram S4 positioning the lever C on S4.- Operate the lever to control the ram descent S4.

N.B. The lever, if in other positions, does not allow any operations as a security device keeps it in free position.

(!) ATTENTION (!) During the stabilisation operations, for each outrigger ram, it isrecommended to DESCENT the outrigger as last manoeuvre.

(!) ATTENTION (!)The complete extension of the outrigger supports is visually indicated bythe yellow triangles which are found at the end of the beam. (Fig. 23b)

The stabilization has to be carried out with care and gradually keeping thevehicle in horizontal levelled condition to prevent springs overloads andchassis torsions.

After having completed the descent and stabilisation manoeuvres, closethe taps of the valves placed on the outrigger rams.

Manoeuvres for re-entry of the crane outriggers and sup-plementary outriggers within the overall vehicle widthafter crane use.

- Position lever D of oil diverter crane-outriggers ( - E/S) onE/S. Fig. 20b

- Open all the taps of the valves placed on the outrigger rams (fig. 22).

(!) WARNING (!) Under no circumstances put the hands on the locking devicesof the outrigger supports; The device re-hook (lever A fromposition of fig. 23b to fig. 23) is automatic.

Crane distributor side

- Select the outrigger ram S2 positioning the lever C on S2.- Operate the lever to control the re-entry of the ram S2.- Select the outrigger support E2 positioning the lever C on

E2.- Operate the lever to control the re-entry of the support E2.- Select the ram S3 positioning the lever C on S3.- Operate the lever to control the re-entry of the ram S3.

A

fig. 23

fig. 23a

fig. 22

fig. 20b

D:E-S

c IX

18

CONTROLS TO STABILIZE THE VEHICLEV2_GR4_160»190

- Select the support E3 positioning the lever C on E3.- Operate the lever to control the re-entry of the support E3.

NB The lever, if in other positions, cannot be operated as a safetydevice keeps it in neutral position.

Double control side

- Select the ram S1 positioning the lever C on S1.- Operate the lever to control the re-entry of the ram S1.- Select the support E1 positioning the lever C on E1.- Operate the lever to control the re-entry of the support E1.- Select the ram S4 positioning the lever C on S4.- Operate the lever to control the re-entry of the ram S4.- Select the support E4 positioning the lever C on E4.- Operate the lever to control the re-entry of the support E4.

NB The lever, if in other positions, cannot be operated as a safety device keeps it in neutral position.

(!) Always check that the outriggers supports, once in their rest position, are locked in their seat by the safety devices, so asto assure the impossibility of accidental movements. (Fig. 23)

(!) It is compulsory to close the outriggers rams valves tapsbefore moving the truck. (Fig. 22)

Tiltable outrigger rams (on request)

Outrigger rams which allow to be rested in an inclined position, whenobstructions on the vehicle chassis prevent their vertical stowability.They are supports with articulation to be put between the outrigger sup-ports and rams; the fixed part is screwed to the outrigger supports andthe mobile one to the outrigger rams.

After the extension of the lateral outrigger supports, place the outriggerram in a working condition as follows:- Remove the check pin and the locking pin from their position

(fig. 24), hand carrying the ram.- Carefully position the ram, insert the locking pin in its new seat and

secure it with the check pin (fig. 24a).

To re-position the rams in folded condition:- Remove the check pin and the locking pin from their position.- Carefully rotate the ram in a upward direction, insert the locking pin in its

new seat and secure it with the check pin.

(!) The locking pin is constructed from special material- do not replace it with a non original part - your security depends on it

fig. 23b

fig. 24a

fig. 24

fig. 25

c XCONTROLS TO

OPERATE THE CRANEV2_GR3_105»140_4

19

CONTROLS TO OPERATE THE CRANE

(!) WARNING (!)Before operating the crane it is compulsory to set the outriggers and toshut the safety check valve taps.

This coincides with that indicated on the plate DE319 placed on the outriggers(Fig. 25)

(!) Operate the levers smoothly and gradually.When carrying out simultaneous movements of two or morefunctions, also related to pump flow and lever travel, it is possiblethat on reaching the stroke end of a particular function, an increasein speed of the other functions will occur.

(!) WARNING (!)While exiting and folding the crane, you must operate from the distri-butor side; it is forbidden to operate from the double control sidebecause of the overall dimensions of the booms. (DE1684A fig. 30)

The symbols placed over each lever define their function in relation totheir movement.

The crane and hydraulic implements can be operated with:– manual controls (distributor and double control) placed on the base;– manual controls (distributor) placed on the top seat;– manual controls (distributor and double control) placed on the base and

hand-cable controls placed on the top seat.

fig. 30

c XCONTROLS TO OPERATE THE CRANEV2_GR3_105»140_4

20

Crane controls - Lever function F - G - H - I (fig. 26-27-28)

F — Rotation controlG — Inner ram controlH — Outer ram controlI — Outer booms section rams control

Hydraulic implements controlsLever function L - M - N(fig. 26-27-28)

L — First hydraulicimplement.

M — Secondhydraulicimplementcontrol.

N — Third hydraulic implement control.

Always remember that the number of levers for hydraulic imple-ments controls changes upon the type of fittings, as follows:

1 lever Winch or bucket control 2 levers Rotator - bucket or jib outer ram - jib extension

rams control 3 levers Jib outer ram - jib extension rams - winch control

Distributor side fig. 26

I H G F

N M L

F G H I

L M N

Double control side fig. 27

F G H I

L M N

From top seat fig. 28

fig. 29

Manoeuvres to unfold the crane into a working condition (fig. 32)

– Engage the power take off.– Stabilize the vehicle as described on Chapter IX.

(!) IT IS FORBIDDEN TO OPERATE FROM (!)THE DOUBLE CONTROL SIDE

(!) Operate from ground control distributor side (!)

— Operate the lever I (re-entry) to ensure that the extension booms are re-entered.

— Before lifting the inner boom, be sure that the outer ram is closed (operate the lever H re-entry function).

— Lift the inner boom over the horizontal line, by operating lever G.(fig. 30)

— Open the outer boom to the “horizontal” position by operating lever H.— (Eventually) extend the booms of the crane by operating lever I. — Position the hook on the vertical line above the load, operating

lever F (rotation).

Manoeuvres to fold the crane into the rest condition

(!) IT IS FORBIDDEN TO OPERATE FROM (!)THE DOUBLE CONTROL SIDE

(!) Operate from ground control distributor side (!)

— Fold the extension booms to their stroke end.— Lift the inner boom to its stroke end.— Fold the outer boom to its stroke end.— Operate the rotation control until the arrows placed on the base and on

the column (dust cover) coincide.— Fold the inner boom to its stroke end; the rest locating pin locates

into its seat. Fig. 30— Lift and re-enter the outriggers to within the overall vehicle width as

described at page 16.

c XCONTROLS TO

OPERATE THE CRANEV2_GR3_105»140_4

21

fig. 30

Load manoeuvres

(!) Before manoeuvering the load, verify that the working area is suitable for your crane.

When a sector of the working area exists in which the stability is insufficient(for example in the area in front of the cab) the permitted arc of rotation islimited by means of an adjustable electro-hydraulic device which only allowsoperation within the safe area. When exceeding the “safe area” the rotationlimiting device only allows manoeuvres which reverse the direction of rota-tion. The lifting curves of the capacity plate indicate the maximum load thatthe crane can lift at a certain radius and at a certain height.To utilize the maximum capacity of the crane, it is necessary to positionthe inner boom as indicated on the capacity plate; the coloured symbolson the inner boom and column must coincide.

During load handling, do not exceed the reach limits given, or the loadindicated on the above mentioned charts. If the limits are exceeded, the load limiting device, allowing all manoeuvres,which reduce the lifted load within the permitted reach limits and forbid allother manoeuvres, will be immediately activated.

(!) The presence of the lifting moment limiting device does not release theuser from the observance of the capacity plates and lifting curves.

c XCONTROLS TO OPERATE THE CRANEV2_GR3_105»140_4

22

USE OF IMPLEMENTS

The crane can be provided with implements such as:

— Manual extensions— Winches— Hydraulic extensions— Personnel baskets.

(!) When using an implement it is always necessary to check that its weight, dimension and capacity is matched to the crane performances.

Warning and norms for crane use also apply for hydraulic implement use.

(!) Before using a personnel basket it is necessary to provide the crane withthe safety devices requested by the local norms in force. Prior to use of the crane it has to be tested and inspected in accordance with the local legal requirements.

USE OF IMPLEMENTSV2_GRU_FASSI

23

c XI

Manual extensions

Manual extensions are additional boom sections, which are placed in thecrane outer booms and secured by pins and check pins; they have a maxi-mum capacity, indicated on the plate, independent from the crane configura-tion.

(!) WARNING (!)

Manual extensions are not protected by the lifting moment limiting device.Before lifting the load make sure that its weight does not exceed thecapacity indicated on the plate.

Manual extensions can be extracted from the rest position and be operative,once the security pins have been removed, with the outer boom in slidingposition.

(!) Verify that the area is suitable for this operation and there are nounauthorized persons in the working area.

Do not permit the extension to slide out at speed as this will damage the stroke end stops.

Do not try to align the holes (slots) for the locking pins with your fingers;always use a suitable tool.

Always remember that when operating with implements, their tare weightmust be deducted from the capacity of the crane.

When manual extensions are in place, fit the locking pins and secure themwith the check pins to prevent accidental escape.

USE OF IMPLEMENTSV2_GRU_FASSI

24

c XI

Winch (fig. 31)

The winch is made of a drum (pos.1) that can rotate by means of a hydraulicengine (pos. 2), on a structure (pos. 3) fixed on the crane (i.e. under the outerboom). The rotation of the drum on which the cable winds is achieved by ahydraulic motor (pos. 2) connected to the circuit by means of hoses; in case offittings or hoses brake the stop of the rotation is guaran-teed by a safety check valve (pos. 4). A parking brake inte-grated to the motoreducer group prevents the rotation onthe drum (held of the winch load in position), when the con-trol function is not activated (lever N in neutral position).

The winch is identified by a plate (fig. 31a) indicating theessential data and fixed by the manufacturer:

Manufacturer mark ...Winch type ...Serial number ...Maximum line in N at the 4th layer...Maximum speed in m/min ...

(!) See operator winch manual supplied by the winches’manufacturer.

The winch has a maximum capacity, indicated by a plate, not related to thecrane capacities which can also be lower.

Consequently avoid to lift, with the winch, heavier loads than those allowedby the crane capacity plate.

The couple limiter, installed on the winch structure, prevents that on the cable,can be created a load major to the value of maximum line at the 4th layer,quiescing all the crane controls.

(!) Under no circumstances interfere with the limiter device adjustment.

Do not rotate the crane before the load is lifted, rotate slowly and with care thesuspended load checking the stability of the vehicle.

The presser-cable always keeps the cable in tension easing the regular rewin-ding and without overlappings on the drum.

(!) On winches not equipped with pressafune, check the rewinding of thecable on winch drum proceeds regularly and without overlapping: it issuggested not to rewind the cable if it is not sufficiently taut.

According to the actual norms the winches must be provided with safety devi-ce. That adopted one uses an electrohydraulic technology, where a signal,given by a microswitch, controls the quiescing and the reactivation of cranecontrols through an electrovalve.

The adopted device prevents that:- in the lifting with the winch or in the booms extension rams exit (crane or

hydraulic extension) the cable hook (or the block) takes contact with thepulley structure;

- in the unwinding the cable is completely wound from the winch drum(threeturns must be wound at least), causing the controls quiescing.

c XIUSE OF IMPLEMENTS

V2_GRU_FASSI

25

1

2

4

3

fig. 31

To reactivate the controls the lever (fig. 26-27-28), winch control must be acti-vated controlling:- the descent of the cable if the device operation is happened in the lifting

with the winch or in exit with the booms extension rams;- the lifting of the cable if the operation is happened in the unwinding of the

same one.

In the phase of lifting or exit of booms extension rams, the controlof the position about the cable hook (or about the block), asregards the pulley structure, is obtained through a microswitch,which lever is kept in position by a chain balance weight, assem-bled free on the cable.In the quiescing of the crane the keeping in position of the micro-switch lever becomes impossible with the consequent quiescingof controls.

To put the crane in rest position it is necessary to operate in thisway:- withdraw the flying drive (it is assembled on the cable of the

cable winder) from the pin placed near the microswitch, placed on the pulley, assembled on the booms extension rams.

- In case it is a crane with hydraulic extension it is necessary to detach the cable of the cable winder, placed on the crane from the pin of the second cable winder, assembled on the extension.

- Release the cable from all support rings placed on the booms letting that it winds free in the cable winder.

- Insert the flying drive in the pin placed in the cable winder. (fig. 32).

This operation gets active all crane controls to complete the rest position operations.

(!) Please remember that after stabilizing the vehicle and placing the cranein working position it is compulsory to reset the functionality of end stroke device, otherwise the cable could be damaged.

Hydraulic connections between implements and hoses fitted on extensionbooms section. (Fig. 33)

(!) In case of hoses connection to implements through coupling unions it isnecessary to verify that there is no trace of soil, curt etc. on the unionsand inside the seats so as to avoid the oil contamination and consequen-tly wear the tightening “ surface of unions.

(!) WARNING (!)

To ensure that the control corresponds to the implement movement, hydraulicconnections are symmetrically fitted with coupling unions. Never invert suchpositions: movements inversion as well as operating difficulties could occur.

c XIUSE OF IMPLEMENTSV2_GRU_FASSI

26

fig. 32

fig. 33

Hydraulic jibs

The hydraulic jibs, foldable behind the cab, are additional booms, with articu-lation and double hydraulic extension (jib L202) or triple hydraulic extension(jib L203) to be fitted to the outer boom of the crane.

On request and according to the version, the manual extensions ML20, NL20,PL20, can be installed on the outer boom of the jib.

For the crane version “.22 or .23 or .24”The jibs L202 and L203 are fitted by means of the insertion of the extensionconnecting boom into the crane extension boom; the fixing to the crane is ob-tained through locking pins.

The hydraulic connection to the supplementary functions of the crane, is throughquick couplings.

(!) Warnings and norms for crane utilisation apply also for hydraulic jibs use.

(!) Warnings and norms for manual extensions are indicated at page 24.

The model, the version of the crane, the yearof construction and the serial number arestamped on the hydraulic jib in the followingsequence:

*L202*3*001*

NOMENCLATURE OF THE HYDRAULIC JIB

Pos. Description 1 – Connecting boom2 – Locking pins3 – Jib outer ram4 – Jib outer boom5 – Boom extension ram6 – Extension booms7 – Manual extensions (on request)

Manoeuvres to unfold the jib in working condition

- Operate as described to put the crane in working condition (Chapter XI)- Operate lever L to open the outer boom of the jib.- Operate (in case) lever M to extend the jib outer boom sliding sections.- Position the hook on the centerline of the load.

c XIUSE OF IMPLEMENTS

V2_GR4_160»190

26a

serial number

year of construction

model and version / L203

1

2

4

5

3

76

punching

fig. 34

Hydraulic jibs for L202 - L203

Manoeuvres to fold the jib in rest condition

- Re-enter the hydraulic sections of the jib (lever M) and of the crane (lever I).- Lift the inner boom to its stroke end.- Re-enter the outer boom of the jib (lever; a rest bracket with bumper (fig. 35)

assures the positioning.- Re-enter the outer boom of the crane to its stroke end.- Operate, as described, to fold the crane in rest position.

Operations to remove the hydraulic jib from the crane

- Re-enter the jib outer booms sliding sections to their stroke end.- Extend the crane outer ram to its stroke end.- Extend (of at least 1 - 1,5 m) the crane outer booms sliding sections.- Re-enter the outer ram of the jib and the inner ram of the crane to obtain

the two rest brackets of the jib, either lay on the ground, or on the truckbody or, if possible, on a specific rest trestle.

- Remove screwing the locking pins.- Disconnect the jib from the hydraulic circuit of the crane operating on the

quick couplings. - Re-enter the outer booms sliding sections of the crane to free the first

boom of the crane jib.

(!) Assure that the hydraulic jib is adequately stripped to avoid sideturnover. .

c XIUSE OF IMPLEMENTSV2_GR4_160»190

26b

fig. 35

MAINTENANCE INSTRUCTIONS

To assure a long life to the crane, it is necessary to meticulously follow theinstructions.

General lubrication and small repairs can be carried out by the user; repairs of amore complicated nature must be carried out by authorized service personnel.

Spare parts must be original.

Good maintenance and proper use are imperative to maintain efficient useand guarantee the safety of the crane.

At least once a year you must take the crane to a Fassi Service Center for acheck.

(!) Before disconnecting any hydraulic hoses, ensure that there is no pressure in the hydraulic circuit. After removing hoses always mark them and their respective ports on the crane. Faulty replacement can cause damage tothe rams and to the hydraulic circuit.

Respect the information supplied for maintenance and technical assistance.

Any maintenance operation must be carried out with the crane powersource turned off. (in case of fixed mounting with hydraulic power pack, theelectric motor has to be turned off).

Do not place limbs, fingers or any other parts of anatomy into areas of thecrane, which present possibilities of shearing, without having blocked such parts of the crane.

Do not weld, drill or grind any part of thecrane without the Manufacturer’s authorisa-tion.

Do not weld the column support (cast ironfig. 36 DE815).

Do not weld the security bolts of the columnsupport of cast iron at the base (see plateDE1574 fig. 37)

Do not weld the fixing rods of the crane (seeplate DE1574 fig. 37).

When repairs to, or checks of, the hydrauliccircuit and of the rams are carried out, it isvery important not to use, or be in the proxi-mity of, materials which can damage the cir-cuit or contaminate the hydraulic oil eg.metal shavings, sand or dust.

Do not use the high pressure washing on the controls (deviators, distribu-tors, double controls, hand cable controls...), on the electronic compo-nents (boxes, control panels...), on the tanks.

Never use detergents, petrolsol or inflammable liquids, always use nonflammable or non toxic liquids.

To avoid down time, it is recommended to periodically carry out the fol-lowing checks.

c XIIMAINTENANCEINSTRUCTIONS

V2_GR4_160»190

27

TIRANTI: NON SALDARE!

FIXING ROD: DO NOT WELD!

TIRANTS: NE PAS SOUDER!

ZUGSCHRAUBEN: NICHT SCHWEISSENDE1574

GHISA: NON SALDARE!

CAST IRON: DO NOT WELD!

FONTE: NE PAS SOUDER!

GUSSEISEN: NICHT SCHWEISSEN!DE815

fig. 37

fig. 36

c XII

Check that all safety devices are efficient.

Check the level of the hydraulic oil in the tank.

Check the hoses fittings and all the components of the hydraulic circuit forpossible leaks.

Check that the oil diverter levers can easily be positioned and that the multi-function control levers of the crane operate freely and return to neutral posi-tion.

Check that the control levers of the crane can easily be positioned (distributor,double controls and hand-cables) operate freely and return to neutral position.

Check the condition of shackles, hooks, wire ropes and any other lifting equipment.

Check the tightening torque of the fixing rods of the crane. (Fig. 38)

Tightening torque for the rods is M24x2 = 400 Nm from the pendulum side Tightening torque for the rods is M30x2 = 471 Nm from the stabilizers side

Clean the oil filter placed in the oil tank of the crane and if any, on the pumpsection and pressure hoses.If the hydraulic circuit of the crane is connected to a tipper a remote oil tankmay be fitted, in this case the filter will be found in this tank.

Cleaning of the filter on the tank (oil return from the distributor) fig. 39

— Remove the filter cover, pos. 1, by unscrewing the three security bolts.Remove the spring and extract the filter cartridge pos. 2: during thisoperation take care that no contaminated material passes into the tank.

— Clean the cartridge by flushing with a non flammable and non toxic solvent.Thoroughly dry the filter inside and out with compressed air.

— Remove the filter holder from the filter body pos. 3 (a hose is attached to itsbase); clean and reassemble checking the sealing ‘O’ rings pos. 4-5 (internal seal between cartridge and holder and external seal between holder and body).

— Re-assemble the filter cartridge into its holder, re-assemble the spring and thefilter cover pos. 6 (check the sealing of the ‘O’ ring under the filter cover).

— Re-fit the three security bolts.— Check for leaks when the pump is activated.

Check the oil level in the tank with the crane inthe folded position and with the outriggers(crane and supplementary) fully re-entered.The oil level must not exceed the maximum orbe lower than the minimum (Fig. 40).Top up using hydraulic oil with the same cha-racteristics as those indicated in the table onpage 40.

28

MAINTENANCEINSTRUCTIONSV2_GR4_160»190

After the first 40 hours use

After every working week

At the end of every working day

fig. 38

fig. 39

MAXM I N

fig. 40

c XIIMAINTENANCEINSTRUCTIONS

V2_GR4_160»190

29

Periodically grease the points indicated on the crane (fig. 41) (and on thehydraulic jib, when fitted, fig. 42) paying particular attention to the points noteasily detected.

— Fig. 43 shows the guide shoe lubricator for the column rotation.— Fig. 43a-43b show the lubricators of the column symmetrically positioned

on the column support.— Fig. 43c shows the lubricator of the pendulum beam.— Fig. 44-44a-44b show the lubricators of the inner and outer rams.— Fig. 45-45a show the lubricators of the pin articulation column - inner boom -

and inner boom - outer boom.— Fig. 46 shows the lubricator of the multifunction return deviator.

When the hydraulic jib is fitted

— Fig. 47-47a-47b show the lubricators of the articulation pins for connecting boom - jib outer boom and fork.

— Fig. 47c-47d show the lubricators of the jib outerboom and of the fork.

For the sliding sections of the extension booms ofthe crane (fig. 48) and of the hydraulic jib (fig. 48b)and of the outrigger supports (fig. 48a) guideshoes made from a special material have been fit-ted: to ease their movement it is recommended tosmear a light film of grease on them, taking carethat the surfaces of the extension booms are freefrom impurities such as sand etc.

Use a grease with the same characteristics indica-ted in the table on page 40

fig. 41fig. 42

fig. 43

fig. 43b

fig. 43a

c XIIMAINTENANCEINSTRUCTIONSV2_GR4_160»190

30

Check the tightening torque of the tie rods fixing the crane to the vehicleframe.

Check the tightening torque of the securing bolts for the ram pins.

Check the guide shoe wear as it affects the sliding section tolerances; if theclearances are considerable, damage to the rams and the structure mayoccur.

Replace the oil filter cartridges.

Clean the air filter placed in the top of the oil tank filter cap.

Completely replace the hydraulic oil.

(!) The waste oil must be disposed of by authorized persons.

After every 500 working hours

fig. 48 fig. 48a

fig. 44

fig. 44a fig. 44b

fig. 45afig. 45 fig. 46

fig. 43c

fig. 47

fig. 47a fig. 47b fig. 47c fig. 47d

fig. 48b

c XIIIPOSSIBLE FAULTS

V2_GR4_160»190

31

POSSIBLE FAULTS

Many years experience of our product has allowed us to identify and classifythe most common faults which occur. In most cases it requires accuratehydraulic and electric troubleshooting and simple rectification. In the followingtable we report the most frequent inconveniences and our suggested remedies.

(!) Checking and adjustment of oil pressures of valve settings must be carried out by an authorized service agent, under penalty of warranty forfeiture.

Operations which can be carried out by the user.

Faults Cause Remedies

The crane does not rotate Vehicle non in level position Stabilize the vehicleproperly

Lack of lubrication Grease the bushes

The extension booms do Lack of lubrication of the Grease the guide shoesnot completely extend or guide shoeswork jerkily

Crane controls are not Lack of electric energy Check the fuse, the bat-active tery and electric circuit

Winch end stroke active See Chapter XI

The rotation limiting deviceis activated See Chapter VIII

Vibrations in crane Shortage of oil Check the level andoperations top up if necessary

Obstructed filters Clean or replace the filtercartridge

Noteable decrease in Obstructed filters Clean or replace the filtermovement speed cartridge

Operations to be carried out by a service center.

Faults Cause Remedies

The crane does not lift the Non efficiency of the Replace the pumploads indicated on the pump capacity plate Main pressure valve not Check the pressure,

properly adjusted, blocked adjust the valveor out of serviceRam seals are not properly Replace the sealsfitted

A boom of the crane does The safety check valve of Replace the valvenot hold up the load and the ram is openvisually lowers Oil leaks inside the ram Defective seals, replace

them

The crane does not rotate Valves controlling the Adjust the valvesproperly rotation not adjusted

Relief valves of the Adjust the valvesdistributor not adjustedWear of the seals of the Replace the sealsrotation cylinder

The extension booms do Wear of guide shoes Check the guide shoesnot completely extend or wear, replace if necessarywork jerkily

Vibrations in crane Non efficient pump Check the pumpoperations

Noteable decrease in Non efficient pump Check the pumpmovement speed

c XIV

32

HYDRAULIC ANDELECTRIC SCHEMATICSV2_GR4_160»190

HYDRAULIC AND ELECTRIC SCHEMATICS

Hydraulic schematic for crane with HCD4 distributor - ground controls - lifting moment limiting device “intelligent type”

c XIVHYDRAULIC AND

ELECTRIC SCHEMATICSV2_GR4_160»190

33

Hydraulic schematic for crane with HCD4 distributor - top seat controls - lifting moment limiting device “intelligent type”

c XIVHYDRAULIC ANDELECTRIC SCHEMATICSV2_GR4_160»190

34

Hydraulic schematic for crane with Danfoss distributor - lifting moment limiting device“intelligent type”

c XIVHYDRAULIC AND

ELECTRIC SCHEMATICSV2_GR2_95_3_4

35

fig. 48

Electric schematic for crane - arc of free rotation

CODE DESCRIPTION

ALIM FEED MAIN CONTROL PANEL.AV ACOUSTIC ALARMLP ADDITIONAL FLASHINGFUSE PROTECTION FUSE 10 A.D1-D2 LAMPS TEST DIODESD3 POLARITY PROTECTION DIODEEV1 EMERGENCY ELECTROVALVEEV2 ELECTROVALVE FOR CRANE LIFTING BLOCKEV3 ELECTROVALVE FOR CRANE DESCENTS BLOCKMS MERCURY SLOPE SENSOR ON OUTER BOOMP1 LOAD PRESSURE 90% DETECTORP2 BLOCK PRESSURE DETECTORLB WHITE WARNING LIGHTLG1 YELLOW WARNING LIGHT FOR MAIN CONTROL

PANEL 90% LOAD REACHINGLG2 YELLOW WARNING LIGHT FOR DOUBLE

CONTROL SATELLITE 90% LOAD REACHINGLG3 YELLOW WARNING LIGHT FOR ADDITIONAL

SATELLITE 90% LOAD REACHINGLR1 RED WARNING LIGHT FOR MAIN CONTROL

PANEL BLOCK

LR2 RED WARNING LIGHT FOR DOUBLE CONTROL SATELLITE BLOCK

LR3 RED WARNING LIGHT FOR ADDITIONAL SATELLITE BLOCKPE1 MAIN CONTROL PANEL STOP BUTTONPE2 DOUBLE CONTROL SATELLITE STOP BUTTONPE3 ADDITIONAL SATELLITE STOP BUTTONPC1 ACOUSTIC WARNING BUTTON FOR MAIN

CONTROL PANELPC2 ACOUSTIC WARNING BUTTON FOR DOUBLE

CONTROL SATELLITEPC3 ACOUSTIC WARNING BUTTON FOR ADDITIONAL

SATELLITESAT2 DOUBLE CONTROL SIDE SATELLITESAT3 ADDITIONAL SATELLITEAR1 CRANE WINDINGAR2 EXTENSION WINDINGLCV WINCH LOAD LIMITING DEVICEMV1 PULLEY MICRO WINCHMV2 DRUM MICRO WINCHLV1 MICRO LEVER FOR CABLE WINDING REACTIVATION LV2 MICRO LEVER FOR CABLE UNWINDING REACTIVATION

fig. 49

Electric schematic for crane - limited arc rotationc XIV

HYDRAULIC ANDELECTRIC SCHEMATICSV2_GR2_95_3_4

36

CODE DESCRIPTION

ALIM FEED MAIN CONTROL PANEL.AV ACOUSTIC ALARMLP ADDITIONAL FLASHINGFUSE PROTECTION FUSE 10 A.D1-D2 LAMPS TEST DIODESD3 POLARITY PROTECTION DIODEEV1 EMERGENCY ELECTROVALVEEV2 ELECTROVALVE FOR CRANE LIFTING BLOCKEV3 ELECTROVALVE FOR CRANE DESCENTS BLOCKIP1 CLOCKWISE ROTATION PROXIMITYIP2 ANTICLOCKWISE ROTATION PROXIMITYSDP SEAT PROXIMITY SHUNT BOXMR1 CLOCKWISE ROTATION RELAYMR2 ANTICLOCKWISE ROTATION RELAYLMR1 CLOCKWISE ROTATION MICRO REACTIVATIONLMR2 ANTICLOCKWISE ROTATION MICRO REACTIVATIONMS MERCURY SLOPE SENSOR ON OUTER BOOMP1 LOAD PRESSURE 90% DETECTORP2 BLOCK PRESSURE DETECTORLB WHITE WARNING LIGHTLG1 YELLOW WARNING LIGHT FOR MAIN CONTROL

PANEL 90% LOAD REACHINGLG2 YELLOW WARNING LIGHT FOR DOUBLE

CONTROL SATELLITE 90% LOAD REACHING

LG3 YELLOW WARNING LIGHT FOR ADDITIONAL SATELLITE 90% LOAD REACHING

LR1 RED WARNING LIGHT FOR MAIN CONTROL PANEL BLOCK




CONTROL SATELLITEPC3 ACOUSTIC WARNING BUTTON FOR ADDITIONALSATELLITESAT2 DOUBLE CONTROL SIDE SATELLITESAT3 ADDITIONAL SATELLITEAR1 CRANE WINDINGAR2 EXTENSION WINDINGLCV WINCH LOAD LIMITING DEVICEMV1 PULLEY MICRO WINCHMV2 DRUM MICRO WINCHLV1 MICRO LEVER FOR CABLE WINDING REACTIVATION LV2 MICRO LEVER FOR CABLE UNWINDING REACTIVATION

c XIVHYDRAULIC AND


37

fig. 50

Electric schematic for crane - diversfied arc rotation

CODE DESCRIPTION

ALIM FEED MAIN CONTROL PANEL.AV ACOUSTIC ALARMLP ADDITIONAL FLASHINGFUSE PROTECTION FUSE 10 A.D1-D2 LAMPS TEST DIODESD3 POLARITY PROTECTION DIODEEV1 EMERGENCY ELECTROVALVEEV2 ELECTROVALVE FOR CRANE LIFTING BLOCKEV3 ELECTROVALVE FOR CRANE DESCENTS BLOCKEV6 ELECTROVALVE FOR CRANE LIFTING MOMENT

LIMITING DEVICE OF THE TWO WORKING ZONESEV7 ELECTROVALVE FOR LIMITING GENERAL PRESSIONIP1 CLOCKWISE ROTATION PROXIMITYIP2 ANTICLOCKWISE ROTATION PROXIMITYSDP SEAT PROXIMITY SHUNT BOXMR1 CLOCKWISE ROTATION RELAYMR2 ANTICLOCKWISE ROTATION RELAYLMR1 CLOCKWISE ROTATION MICRO REACTIVATIONLMR2 ANTICLOCKWISE ROTATION MICRO REACTIVATIONMS MERCURY SLOPE SENSOR ON OUTER BOOMP1 LOAD PRESSURE 90% DETECTORP2 BLOCK PRESSURE DETECTORP4 ROTATION CONTROL PRESSURE DETECTORLB WHITE WARNING LIGHTLG1 YELLOW WARNING LIGHT FOR MAIN CONTROL

PANEL 90% LOAD REACHING

LG2 YELLOW WARNING LIGHT FOR DOUBLE CONTROL SATELLITE 90% LOAD REACHING

LG3 YELLOW WARNING LIGHT FOR ADDITIONAL SATELLITE 90% LOAD REACHING

LR1 RED WARNING LIGHT FOR MAIN CONTROL PANEL BLOCK




CONTROL SATELLITEPC3 ACOUSTIC WARNING BUTTON FOR ADDITIONALSATELLITESAT2 DOUBLE CONTROL SIDE SATELLITESAT3 ADDITIONAL SATELLITEAR1 CRANE WINDINGAR2 EXTENSION WINDINGLCV WINCH LOAD LIMITING DEVICEMV1 PULLEY MICRO WINCHMV2 DRUM MICRO WINCHLV1 MICRO LEVER FOR CABLE WINDING REACTIVATION LV2 MICRO LEVER FOR CABLE UNWINDING REACTIVATION

c XIVHYDRAULIC ANDELECTRIC SCHEMATICSV2_GR2_95_3_4

38

CONTROL PANELS

control panel cover

top seat satellite

fig. 52

fig. 51

c XIVHYDRAULIC AND


39

double control satellite

fig. 53

c XV

40

OIL AND LUBRICANTCHARACTERISTICSV2_GR2_95_3_4

TABLE OF HYDRAULIC OIL AND LUBRICANTS CHARACTERISTICS

Minimal external maximal oiltemperature : temperature:

– 35°C + 45°C Gradation ISO VG 32– 20°C + 75°C Gradation ISO VG 46

Minimal external maximal oiltemperature : temperature:

-10°C + 60°C Gradation ISO VG 32+ 0°C + 75°C Gradation ISO VG 46+ 5°C + 85°C Gradation ISO VG 68+10°C + 90°C Gradation ISO VG 100

Consistency: NLGI BEACON EP 2 - BEACON 3

( ! ) WARNING ( ! )Don’t use greases with solid particles as “Bisulphide of Molybdenum”.

HYDRAULIC OIL WITH HIGH VISCOSITY: ISO-L-HV

HYDRAULIC OIL WEAR RESISTANT: ISO-L-HM

GREASE

AINSTRUCTION ANDWARNING PLATES

V2_GR4_160»190

41

INSTRUCTION AND WARNING PLATES

DE 1682 Greasing points at pressure

DE 1681 Greasing points with brush

DE 319Warning plate to stabilize the vehi-cle before using the crane

DE 1771Instruction plate and safety norms

DE 2298

Instruction platesto stabilize thevehicle

DE 2297

AINSTRUCTION ANDWARNING PLATESV2_GR4_160»190

42

TIRANTI: NON SALDARE!

FIXING ROD: DO NOT WELD!

TIRANTS: NE PAS SOUDER!

ZUGSCHRAUBEN: NICHT SCHWEISSEN!

DE1574

GHISA: NON SALDARE!

CAST IRON: DO NOT WELD!

FONTE: NE PAS SOUDER!

GUSSEISEN: NICHT SCHWEISSEN!

DE815

DE 1574Do not weld the fixing rods

DE 815Do not weld the cast iron

DE 1680Do not use water to estinguish fire

DE 1686Do not walk or stop under a suspendedload

DE 1683Do not operate in proximity of electrichigh-tension lines

DE 1684A Do not operate from the double controlside, to unfold or fold the crane

DE 1679Do not walk on...

c I CAPACITY PLATES

For cranes and manual extensions.

The represented plates refer to the nominal design capacities.

! WARNING !

If the capacities are downgraded or partially reduced (e.g. sector in front ofvehicle cab) capacity plates must be applied in line with the final test figures.

43

CAPACITY PLATESF 190.24

BCAPACITY PLATES

F 190.24

44

c I

45


46

BCAPACITY PLATES

F 190.24

c I

47


48

BCAPACITY PLATES

F 190.24

c I

49


BCAPACITY PLATES

F 190.24

50

c ICAPACITY PLATESF 190.24

51

FASSI CRANE

F190FROM SERIAL NUMBER. 1369

Edition 00 29-04-99

This supplementary use and maintenance Booklet is an up-dating of the Useand Maintenance manual of the cranes F190 from serial number 1369.

(!) WARNING (!)Some of the subjects contained are an integration of what reported inthe manual; read carefully this supplementary manual paying attention tothe chapters or contesst of the manual before operating the crane.

Chapter XII MAINTENANCE INSTRUCTIONS page 2

c I

1

c XII

2

MAINTENANCE INSTRUCTIONSF190

MAINTENANCE INSTRUCTIONS

See chapter XII of the USE AND MAINTENANCE MANUAL for details of“Maintenance instructions”.

The following lubricators have been centralized and gathered in a case (fig. 1-1a)positioned on the base (crane distributor side):

- rack guide shoe -rotation, - upper and lower bush of the column - column support, - rack group - column gear - column support group - pendulum beam

Note! All the lubricators mounted on the crane are protected by a plasticcap so to avoid the oil contamination . . .

(!) WARNING (!)At low temperatures, the grease shall not crystallize or, to be more precise,shall not change its characteristics.At the effective operative temperature, the grease we recommend shall have aconsistency at least equal to rating NLGI with value 0 or max 1.

(!) WARNING (!)Centralized lubrication shall not be used when room temperature is below -10°C / -20°C.

fig. 1 fig. 1a

f 190 - fascan international · c i introduction f 190.24 2 fassi crane f 190.24 use and...

Documents